In Mold Lamination Of Decorative Products

ABSTRACT

A method of manufacturing decorative plastic composites having a decorative layer, a backing layer and a clear outer layer which provides exceptional “depth of image” is disclosed. Decorative or protective appliqués&#39; having a wide range of decorative patterns may be formed by injection molding a backing layer behind and a clear outer layer on the top surface of a thin foil, film, fabric or veneer.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of International Application No.PCT/US2005/000170 filed Jan. 3, 2005 and published Aug. 4, 2005 asInternational Publication No. WO 2005/070647, designating the UnitedStates, and which claims benefit of U.S. Provisional Application No.60/533,632 filed Dec. 31, 2003.

FIELD OF THE INVENTION

This invention relates to plastic composites formed by injectionmolding, particularly to plastic composites which find use as decorativeappliqués for motor vehicle trim, and more particularly, to decorativeappliques having a wide variety of decorative patterns which exhibitexceptional “depth of image” provided by a layer of relatively clearplastic forming the outer surface.

BACKGROUND OF THE INVENTION

Transportation vehicles, particularly automobiles, are marketed and soldon the basis of differentiation over other competitive models.Differentiation may be by style or color, and is often accomplished byusing trim panels or appliqués on the interior or exterior of thevehicle which denote different levels of luxury, price or value. Theseappliqués or panels may also form protective coverings for areas thatprotrude from adjacent surfaces. These panels are generallycolor-coordinated with the adjacent surfaces of the vehicle but may alsobe bright, reflective, wood grained, marbleized or metallized inappearance.

Originally, real wood appliqués and finished metal panels were used,however, their popularity suffered due to their high cost and limiteddurability. Subsequently, wood veneers and films with vacuum-depositedmetal layers found favor, however, these solutions did not produce thelook of luxury or the extended durability required in today's market.

Various proposals have been suggested and practiced for the manufactureof plastic composites for use as automotive interior trim and exteriortrim panels or appliqués. One approach has been to form a metal orplastic substrate and apply multiple coatings thereon to produce a highgloss Class A-surfaced part. The substrates may be formed from steel, orany one of a wide range of known plastic materials such as ABS, PP,ABS/PC blends, PU, TPO, PET, PBT or other equivalent high strengthplastic materials suitable for injection molding into a product shape.The coatings for such substrates may be selected from known coatingssuch a primer coat, an adhesion promoter, a base coat and a clear coat,and in the case of metals, an electrodeposition coat. Examples of suchcoatings are set forth in United States Pat. Nos. 4,681,811 and5,320,869. The solvents used in such systems may cause undesirableenvironmental and emission problems.

Another approach is to form a paint film and inject polymeric materialbehind the paint film to produce a part with a desired colormatch on itsexposed Class A surface. Examples of known paint film and injectionmolded plastic parts are disclosed in U.S. Pat. Nos. 5,432,666 and5,009,821. Such systems may require the separate manufacture andhandling of the film. Furthermore, the outer surface being a paint filmmay not exhibit an exceptional depth of image and may be readilyscratched or abraded.

Still another approach to providing a colored plastic part is to providean enamel coating that will reduce emissions while producing a craterresistant surface on the part being coated. One such system is set forthin U.S. Pat. No. 4,396,680. Such systems may require the use ofexpensive conventional coating systems and baking ovens to form a finishon the substrate that has the desired appearance.

Yet another approach is to provide laminating equipment in which a colorlayer is formed by extrusion and then connected to a substrate. U.S.Pat. No. 4,349,592 discloses the use of such a technique in themanufacture of a decorative molding exterior trim part.

Various other proposals have been suggested to produce decorative trimparts and appliqués which have unique decorative patterns, highdistinctness of image (DOI) and exceptional “depth of image” which givethe impression of luxury and high value. “Depth of image” is hereindefined as the emphasis of a decorative pattern by a preferably clearresin layer overlying it, which provides the appearance that the patternlies deep beneath the top surface of the clear outer layer. This isderived from wood finishing where multiple layers of wax or coatings areapplied and buffed out to provide a grain pattern that appears to liewell below the top surface or has depth.

For instance, U.S. Pat. No. 5,338,592 is directed at laminating a seriesof wood veneers to form an overlay sheet, finishing, cutting and dryingthe overlay to form a shape, molding a transparent resin layer onto thefront surface of the wooden shape and molding a synthetic resin corematerial onto the rear surface of a wooden shape. However, the effort offorming the wooden veneer overlay to the desired shape is both timeconsuming and costly.

Similarly, U.S. Pat. No. 5,525,179 is directed at manufacturing a liningpart comprising a blank having a preformed shape and a cutout with anedge, injection molding a first plastic material to form a back surface,followed by injection molding a second plastic material to form a frontsurface coating which also coats the edges of the part. Again, apreformed shape is disclosed.

As disclosed in the '179 reference, German Published Application 41 24297 describes a similar process using a preshaped blank and employingpolymethyl-methacrylate (PMMA) as the outer layer. However, thisreference does not disclose the use of a plastic backing layer.

U.S. Pat. No. 6,444,317 is directed at preparing a laminate filmincluding a polyolefin film layer and a primer layer and injectionmolding a polyolefin resin onto the polyolefin film layer to form anouter layer.

Regarding decorative wood articles, U.S. Pat. No. 6,444,319 assigned toErwin Behr, GmbH & Co. is directed at surface coating of an interiorfitting for vehicles with a lacquer or resin layer wherein a wood veneercomponent is inserted into a mold and spaced from the cavity so that aliquid surface coating material having at least two mixed components maybe introduced into the space between the mold and wood veneer component.United States Patent Application Publications Nos. 2003/0044598 and2003/0162045, also to Behr, disclose the use of a liquid coatingmaterial curable by UV radiation, and the application of a coatingmaterial based on vegetable-oil-modified resin and natural vegetableoils, with the addition to the coating material of ceramicmicro-particles, respectively.

Finally, United States Patent Application Publication No. 2002/0007898is directed at a method of making a molded wood part having a wood grainpattern wherein a wood fiber substrate is formed, coated with a waterimpermeable substrate and a pattern transferred to the substrate using ahydrographic process. A protective top coat may be applied over thepattern. One example of a hydrographic process is disclosed in U.S. Pat.No. 4,010,057 wherein a thin film on which a pattern is printed isfloated on the surface of a liquid and the pattern is transferred ontothe surface of the object by submerging the surface of the object in theliquid.

While the various methods are suitable for their intended purpose, theyall involve processing considerations that either produce emissions,require heavy capital investment in facilities or require unnecessaryhandling of one or more layers of material in the manufacture of adecorative exterior or interior trim product and do not produce anexceptional depth of image of the decorative layer.

Thus, there is a continuing need in this field of art for an article andits method of manufacture that will obviate the above problems.

SUMMARY OF THE INVENTION

The present invention relates to a production method for providing atrim panel or appliqué wherein a decorative layer is positioned betweentwo mold halves and a plastic material is injection molded against onesurface of the decorative layer to form a decorative composite.Subsequently, the decorative composite is transferred to a second toolwhere a, preferably clear, plastic material is injection molded againstthe other side of the decorative layer.

The plastic materials may be of the same or different composition, butpreferably one of the materials is a relatively clear transparentplastic which when provided at an appropriate thickness, yields anappearance of the decorative layer lying under the top surface of theclear layer, thus having an exceptional depth of image.

The decorative layer may comprise a wide variety of thin materials todistinguish its appearance, including, but not limited to; fabric, wood,foil, metal and plastic. The process may be carried out using multiplemold cores and covers to form the plastic layers on each side of thedecorative layer. In this instance, the decorative composite laminate isformed in one mold set and travels with a first mold core tosubsequently align with a second mold cover to provide a cavity spacefor molding an outer layer against the outer or top side of thedecorative layer. Alternatively, the decorative composite may bedemolded from the first mold set and placed in a second mold set havinga cavity space which will allow the molding of a plastic materialagainst the other side of the decorative layer.

In a most preferred embodiment, the injection mold core and cavity aredesigned with a extended shear edge which allows the aligned core andcavity to be separated, after the decorative layer and base layer havebeen formed, by an amount substantially equal to the thickness of theclear outer layer, to form the final composite structure for an appliquéor trim panel.

Accordingly, it is an object of the present invention to provide amethod of providing trim panels or appliqués having a wide variety ofdecorative patterns covered by an outer layer of injection molded,preferably clear, plastic which provides an exceptional depth of imageand luxurious appearance.

It is a further object of the present invention to provide appliqués andtrim panels having an injection molded outer layer which provides anexceptional depth of image and luxurious appearance.

It is a still further object of the present invention to form appliquésand trim panels having a distinctive appearance wherein one or more ofthe injection molded or decorative layers include pigments, metallicflakes, tints, and/or reflective fibers which provide a unique coloreffect.

Another object of the present invention is to provide a tool design foran injection mold whereby an extended shear edge allows the same moldset to be used to provide successive layers of injection molded plasticon both sides of a decorative layer.

It is a further object of the present invention to form appliqués ortrim panels having exceptional depth of image wherein the decorativelayer is formed to final shape by the injection molding of the first,preferably clear, material against it.

It is a still further object of the present invention to provide aprocess for producing appliqués or trim panels having exceptional depthof image and decorative alternatives which are much thinner incross-section than are presently available.

It is a still further object of the present invention to providefastening means for thin-walled decorative appliqués or trim panels.

Still other objects and advantages of the present invention will becomereadily apparent to those skilled in the art from the following detaileddescription, wherein it is shown and described preferred embodiments ofthe invention. As will be realized the invention is capable of other anddifferent embodiments, and its several details are capable ofmodification in various respects, without departing from the invention.Accordingly, the description is to be regarded as illustrative in natureand not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The features, operation and advantages of the invention may be betterunderstood from the following detailed description of the preferredembodiments taken in conjunction with the attached drawings, in which

FIG. 1 is a perspective view of an automobile instrument panel includingan appliqué of the present invention.

FIG. 2 is a perspective view of an automobile door panel including anappliqué of the present invention

FIG. 3 is an enlarged cross-sectional view of an appliqué or trim panelof the present invention.

FIG. 4 is a simplified cross-sectional view of an apparatus to form thedecorative base layer of one embodiment of the present invention.

FIG. 5 is a simplified cross-sectional view of an apparatus to form thecomposite appliqué of one embodiment of the present invention.

FIG. 6 is a block diagram reciting the steps of a preferred moldingprocess.

FIG. 7 is a block diagram reciting an alternative molding process.

FIG. 8 is a block diagram reciting still another alternate moldingprocess.

BEST MODE FOR CARRYING OUT THE INVENTION

Decorative panels in the form of appliqués and bezels are found in manymarkets; automotive, appliance, marine, furniture, etc. Some of thesepanels also function as protective trim strips along the sides of boatsand cars to prevent minor bumping damage. These panels may take on anyappearance to differentiate the product which they are installed upon.Protective trim appliqués are often bright, reflective metal-appearinglaminates or extrusions with a plastic outer layer. Popular inside thevehicle are “real wood” appliqués that use a preformed wood laminatewhich is coated with a clear plastic layer. A key to thesewood-appearing products is the relatively thick outer coating whichyields a luxurious, expensive-appearing image. The present inventionprovides a molding process for producing thin appliqués havingexceptional decorative appearance and depth without the need to preshapethe decorative layer prior to molding. An appliqué of this type is shownat 10 in FIG. 1. FIG. 1 is a perspective view of the driver's side of anautomobile cockpit with the main instrument panel 20 shown beneath awindshield 24. Beneath the instrument panel, typically, there is ahidden airbag deployment system 26 whose presence is not evident on thetop surface. Decorating the surface of the instrument panel 20, arethree coordinated appliqués 10, 12 and 14 which include a wood grainpattern 16 that flows smoothly from panel to panel. Often this woodappearance flows completely across the instrument panel and along thedoor panels, along each side of the vehicle. By providing an appliquéwith the appearance of lightly buffed expensive wood, the interiorappearance of the vehicle is enhanced and differentiated.

A second decorative appliqué is shown in FIG. 2 where a door panel 30which includes a grab handle 34 and armrest 36 further includes adecorative appliqué 32, in this case having the appearance of a coarselywoven burlap type fabric, appearing to be deeply encased in a clearplastic layer. Other applications for the method and construction of thepresent invention are equally suitable as protective or decorativestrips or panels on the outside of other vehicles, appliances, etc.

The construction of the appliqué or trim panel of the present inventionis shown in simplified cross-sectional view in FIG. 3. The layers asshown are exaggerated in thickness for clarity of the discussion. Therelative dimensions of the layers may not be as depicted.

Here, an appliqué 10 comprises a decorative layer 1 having a front sideand a back side, which may include, but is not limited to, a foil, film,fabric, veneer, coating or thin laminate which is covered with a layer 3of a first plastic on its back side and has a top layer 5 overlying itsfront side. The top layer 5 is preferably injection molded of a clearplastic at a thickness to provide the desired depth of image and toprotect the thin decorative layer 1. The backing layer 3 is alsoinjection molded and may be of nearly any plastic material and may betinted, pigmented or otherwise decorated to enhance the appearance ofthe decorative layer 1, if so desired. Likewise, the top layer 5 may betinted, pigmented or otherwise decorated to yield a specific appearanceas desired. As noted above, typical decorative materials include, but,are not limited to, cloth or fabrics, metallized or painted films, woodgrain veneers, laminates formed by hydrographic or metal depositionprocesses, etc.

A key to the present invention is an uncomplicated process for formingthin appliqués or trim panels. In a preferred embodiment as shown inFIG. 4, a decorative layer 1 is positioned between mold halves. Whenmold core 2 is aligned with the mold cover 4 there is a resulting cavityspace formed for a first plastic 3 to be injection molded behind thedecorative layer 1. This causes the decorative layer 1 to conform to theshape of the mold cover 4 and for the first plastic to fill out thespace between the core 2 and cover 4. The core 2 and cover 4 are alignedby a shear edge 6 which extends around the projected core 2 and closelyinterfaces with the cover 4. In a preferred embodiment the shear edge 6is lengthened so that an additional top layer 5 may be injected (seeFIG. 5) by withdrawing the core 2 out of the cover 4 by an amount, a.The decorative layer 1 in FIG. 4 may be cut to conform to the dimensionsof the space between the core 2 and cover 4 or may extend across theland area of the cover 4 and be held in place, or even cut off by thecore 2 along the shear edge 6 when the core 2 and cover 4 are aligned.

Turning to FIG. 5, it is shown that the core 2 of FIG. 4 has beenretracted out of the cover 4 portion of the mold set by an amount, a,which is preferably substantially equal to the thickness of the toplayer 5 of the appliqué 10. This allows the preferably clear outer layer5 to be injected over the decorative composite formed by the decorativelayer 1 and backing layer 3. The preferably clear outer layer 5 maycomprise any of the clear, preferably light stable, plastics availablein the art, including but not limited to, polycarbonate,polymethyl-methacrylate, thermoplastic urethane, polyester, copolyesteralloys, cyclic olefin copolymer, poly-4-methyl-1-pentene, polysulphone,allyl diglycol carbonate, allyl ester, styrene-acrylonitrile,polystyrene and polyvinyl chloride.

Preferably, the clear plastic outer layer 5 comprises a copolymer andmore particularly a cyclic olefin copolymer, such as TOPAS® 6015S-04from Ticona, or a co-polyester alloy, such as OPTIMUM® 800 Grade fromEngineered Plastics Corporation. The appliqué 10 as formed by the methodof the present invention may be of any thickness suitable for theapplication for which the appliqué is intended, typically from about 1.0mm. to about 5.0 mm. with a clear outer layer 5 typically of about 0.5mm. to about 1.0 mm. in thickness, depending on the molding propertiesof the clear resin used for the outer layer 5.

Unique to the specific construction and method of the present inventionis the ability to mold the appliqué 10 in a single mold set (core 2,cover 4) without having to exchange mold halves to accommodate the outerlayer 5. Also unique is the ability to produce very thin appliqués, ofabout 1 mm. in thickness by a single injection mold set.

The process of a preferred embodiment of the present inventionpreferably comprises (see FIG. 6) the steps of providing a mold core andcover, which cooperate to form a cavity space, in an injection moldingmachine (Block 200); positioning a, preferably thin, decorative layer 1across the mold cover 4 which includes a contoured surface (Block 202);aligning the mold core 2, having a contoured surface which mates with,but is spaced from, the contoured surface of the mold cover, with themold cover 4 to form a first injection volume (Block 204); injecting afirst plastic as a backing layer 3 on to the back side of the decorativelayer 1 and into the injection volume to conform the decorative layer 1to the cover portion and form a decorative composite (Block 206);solidifying the first plastic material and retracting the core 2 alongwith the composite formed by the decorative layer 1 and first plastic 3(Block 208) along lengthened shear edges which allow the tooling toremain substantially sealed; injecting a second plastic onto the frontsurface of the decorative layer 1 to form a preferably clear top layer 5(Block 210); solidifying the second plastic layer 5 and demolding andtrimming the appliqué (Block 212). The invention may also beaccomplished by injecting the clear layer on the front side of thedecorative layer first (at Block 206), retracting the mold core awayfrom the decorative composite, and injecting the backing layer (at Block210). Further, it is contemplated that an appliqué′ may be similarlyformed by co-injecting the two plastic materials on to both the frontand back sides of the decorative at substantially the same time andallowing the injection pressure to open the mold halves to form thefinished appliqué′, or optionally to fill the cavity space between themold halves without moving the mold halves.

Appliques of the present invention may also preferably include fasteningmeans for attachment to other surfaces, including but not limited to,hook and loop, molded bosses which interact with Palnuts, molded Xmastree projections, and sections which snap-fit into adjacent or mountingsurfaces. Alternately, the fastening features may include dielocks,undercuts and various other female features known in the art.

An alternate method of forming the appliqué of the present inventioninvolves a 2 stage process as described in FIG. 7. Here, a first moldcore 2 having a contoured projecting portion and a first mold cover 4having a similarly contoured, preferably recessed, portion spaced fromthe core are aligned to form an injection volume for forming adecorative composite layer (Block 300). A decorative layer 1 ispositioned between the contoured portions of the mold cover 4 and moldcore 2 (Block 302), the mold core 2 and cover 4 are aligned and closed(Block 304) and a first plastic material injected on to the back side ofthe decorative layer 1 to form a backing layer 3 (Block 306). Uponsolidifying, the decorative composite formed of decorative layer 1 andbacking layer 3 is removed from the molds and placed into a second setof molds comprising core 2A and cover 4A (Block 308). Typically, thecontoured projecting portion of the core 2A may be slightly smaller indimension than that of core 2 to accommodate any shrinkage of thebacking layer. Core 2A and cover 4A cooperate to define a secondinjection volume between the mold halves which is greater than thevolume of the decorative composite (Block 310). A second plasticmaterial, preferably clear, is injected into the space between the moldcover 4A and the composite layer outer surface to form a protectiveouter layer 5 (Block 312). Upon solidifying the outer layer 5, theappliqué 10 may be removed from the mold 2A,4A and trimmed (Block 314).Alternatively, the outer layer 5 may be injected against the decorativelayer first (at Block 306) and subsequently the backing layer may beinjected in the second tool set (at Block 312).

A third method for alternatively forming an appliqué of the presentinvention is disclosed in U.S. Pat. No. 6,468,458, commonly assigned tothe assignee of the present invention and included herein by reference.This method, as shown in FIG. 8, includes a two part mold system whereinone of the mold parts is moveable (Block 400) and includes mold covershaving contoured, preferably, cavity portions and the other of the moldparts is stationary and may include a mold core having a similarcontoured surface spaced from the cover. The mold covers and corecooperate to form different injection volumes (Block 402, Block 404) toaccommodate injecting a first plastic behind a decorative layer using afirst mold cover and first mold core (Block 406), and then aligning asecond mold cover which provides a larger cavity area with the firstmold core (Block 410) including the decorative composite to accommodatethe subsequent injection of an outer layer (Block 410). Uponsolidification the finished appliqué′ is removed (Block 412). Themoveable mold parts allow rotation of the mold covers, in this case, toalign with the mold core to allow overshooting of the clear layer. Thisis described schematically in FIG. 8. Alternatively, the outer layer maybe formed first in the cavity portion of a mold cover and subsequentlythat cover containing the decorative composite comprising the decorativelayer and outer layer is aligned with a second mold core having asmaller contoured profile to allow the backing layer to be formedbetween the composite layer and the smaller contoured profile. Further,either of the mold parts, cores or covers, may be attached to either ofthe movable or stationary mold platens. Preferably, the moveable moldpart is carried on a rotary platen that allows the moveable mold part torotate and align with the stationary mold parts. The moveable mold partcarries the composite laminate from station to station and thestationary mold part has a profile that allows space for the injectionof the subsequent layer to form the finished appliqué.

EXAMPLE 1

A thin wood veneer from Kimpara & Co., LTD. of Japan about 0.5 mm. inthickness was placed between the core and cover of an injection mold foran instrument panel applique such as shown in FIG. 1.

A first plastic material, 5135 polypropylene from Huntsman, LLC wasinjected behind the wood veneer layer to conform the layer to the shapeof a contoured cavity area in the mold cover and fill out the cavityspace to form a backing layer. After solidifying the backing layer thecore portion of the mold set was retracted 1.5 mm with the backing layerand decorative layer composite remaining tightly affixed to the moldcore. The resulting cavity space formed by the retraction of the corefrom the cover was filled with a second polymer material, V825poly(methylmethacrylate) from the Atoglas Division of Atofina, thechemical branch of TOTAL. Upon cooling and demolding the applique, awood grained molding having a luxurious appearance was obtained.

EXAMPLE 2

Using the same molding set up as in Example 1, a section of coarselywoven fabric, a circular knit, WF0023 from Collins and Aikman ProductsCo. was positioned between the mold core and mold cover. TOPAS®6015S-04, a cyclic olefin copolymer from Ticona, was injected behind thefabric to shape it to the contoured cavity space in the mold cover andback the fabric with clear polymer. Upon cooling, the mold core wasretracted along with the combined fabric and backing layer and a secondlayer of cyclic olefin copolymer was injected into the open space, thusforming a protective top layer on the fabric. Upon cooling anddemolding, a unique appearing appliqué was formed having an open weavefabric appearance buried deep in a clear layer

INDUSTRIAL APPLICABILITY

Thus, a thin walled decorative appliqué which may function as adecorative or protective surface or edging may be produced using anefficient molding process whereby a thin decorative layer is shaped byinjecting a first plastic material, preferably as a backing layer,behind the decorative layer, and subsequently a second plastic material,preferably a clear polymer, is injected on the opposite side, preferablythe front side of the decorative layer, to form an appliqué. Threepreferred arrangements of mold alignment are disclosed, although otherarrangements may be possible.

The appliqué formed by these methods is distinguished by a wide varietyof thin decorative materials that may comprise the decorative layer, byadditives in the form of tints, pigments and flakes that may be used inthe injection molded layers to emphasize the decorative layer, by theuse of, preferably, a clear polymer as the outer layer of the appliquéwhich provides a unique depth of image which further emphasizes theappearance of the underlying decorative layer, and by the forming of thethin decorative layer by the injection of the first plastic material.

Variations and modifications are possible without departing from thescope and spirit of the present invention as defined by the appendedclaims.

1. A method for manufacturing an appliqué having a decorative layer, abacking layer and an outer layer, comprising the steps of: (a) providinga mold core and a mold cover which cooperate to form a cavity spacewherein said core and cover are aligned along one or more shearingedges; (b) providing a decorative layer having a front side and a backside; (c) placing said decorative layer across said mold cover overlyingat least a portion of said cavity space; (d) aligning said mold core andsaid mold cover to form a first injection volume therebetween; (e)injecting a first polymer against the backside of said decorative layerto substantially conform said decorative layer against the cover side ofsaid first injection volume thereby forming a decorative compositecomprising a backing layer at least partially formed behind saiddecorative layer; (f) solidifying said backing layer; (g) retractingsaid core and said decorative composite from said mold cover along saidone or more shear edges by an amount related to the thickness of anouter layer thereby forming a second injection volume; (h) injecting asecond polymer into said second injection volume against the front sideof said decorative layer to form an outer layer; and (i) solidifyingsaid second polymer to form a molded appliqué.
 2. The method of claim 1wherein the second polymer is a clear plastic.
 3. The method of claim 3wherein said clear plastic comprises any one of polycarbonate,poly(methyl methacrylate), thermoplastic urethane, polyester,copolyester alloy, cyclic olefin copolymer, poly-4-methyl-1-pentene,polysulphone, allyl diglycol carbonate, allyl ester,styrene-acrylonitrile, polystyrene, polyvinyl chloride and blends,alloys and combinations thereof.
 4. The method of claim 1 wherein saiddecorative layer comprises one of a film, a foil, a laminate, a veneer,a fabric and a coating.
 5. The method of claim 4 wherein said veneerincludes a wood grain pattern.
 6. The method of claim 1 wherein one ormore of said first or said second polymers includes one or morepigments, tints, colored dyes, metallic flakes or light reflectiveparticles blended therein.
 7. A method for manufacturing an appliquéhaving a decorative layer, a backing layer and an outer layer,comprising the steps of: (a) providing a mold core and a mold coverwhich cooperate to form a cavity space wherein said core and cover arealigned along one or more shearing edges; (b) providing a decorativelayer having a front side and a back side; (c) placing said decorativelayer across said mold cover overlying at least a portion of said cavityspace; (d) aligning said mold core and said mold cover to form a firstinjection volume therebetween; (e) injecting a first polymer against thefront side of said decorative layer to substantially conform saiddecorative layer against the core side of said first injection volume,thereby forming a decorative composite comprising an outer layeroverlying said decorative composite; (f) solidifying said outer layer;(g) retracting said core along said one or more shear edges from saidmold cover and said decorative composite by an amount equal to thethickness of a backing layer, thereby forming a second injection volume;and (h) injecting a second polymer into said second injection volumeagainst the backside of said decorative layer to form a backing layer;and (i) solidifying said second polymer to form a molded applique. 8.The method of claim 7 wherein said first plastic is a clear plastic. 9.The method of claim 8 wherein said clear plastic comprises any one ofpolycarbonate, poly(methyl methacrylate), thermoplastic urethane,polyester, copolyester alloy, cyclic olefin copolymer,poly-4-methyl-1-pentene, polysulphone, allyl diglycol carbonate, allylester, styrene-acrylonitrile, polystyrene, polyvinyl chloride andblends, alloys and combinations thereof.
 10. The method of claim 7wherein one or more of said first or said second polymers includes oneor more pigments, tints, colored dyes, metallic flakes or lightreflective particles blended therein.
 11. The method of claim 7 whereinsaid decorative layer comprises one of a film, a foil, a laminate, aveneer, a fabric or a coating.
 12. The method of claim 11 wherein saidveneer includes a wood grain pattern.
 13. A method for manufacturing anappliqué having a decorative layer, a backing layer and an outer layer,comprising the steps of: (a) providing a mold core and mold cover whichcooperate to form a cavity space wherein said core and cover are alignedalong one or more shearing edges; (b) providing a decorative layerhaving a front side and a back side; (c) placing said decorative layeracross said mold cover overlying at least a portion of said cavityspace; (d) aligning said mold core and said mold cover to form a firstinjection volume therebetween; (e) injecting a first polymer against theback side of said decorative layer to substantially conform saiddecorative layer against the cover side of said first injection volumethereby forming a decorative composite comprising a backing layer atleast partially formed behind said decorative layer; (f) solidifyingsaid backing layer; (g) retracting said core from said cover andremoving said decorative composite; (h) providing a second mold core andsecond mold cover which cooperate to form a second cavity space; (i)placing said decorative composite upon said second mold core; (j)aligning the second mold cover and second mold core including saiddecorative composite to form a second injection volume; (k) injecting asecond polymer into said second injection volume against the front sideof said decorative layer to form an outer layer; and (l) solidifyingsaid second polymer to form a molded applique.
 14. The method of claim13 wherein the second polymer comprises clear plastic.
 15. The method ofclaim 14 wherein said clear plastic comprises any one of polycarbonate,poly(methyl methacrylate), thermoplastic urethane, polyester,copolyester alloy, cyclic olefin copolymer, poly-4-methyl-1-pentene,polysulphone, allyl diglycol carbonate, allyl ester,styrene-acrylonitrile, polystyrene, polyvinyl chloride and blends,alloys and combinations thereof.
 16. The method of claim 13 wherein oneor more of said first or said second polymers includes one or morepigments, tints, colored dyes, metallic flakes or light reflectiveparticles blended therein.
 17. The method of claim 13 wherein saiddecorative layer comprises one of a film, a foil, a laminate, a veneer,a fabric or a coating.
 18. The method of claim 17 wherein said veneerincludes a wood grain pattern.
 19. A process for manufacturing amulti-layer composite product of injection molded plastic comprising:(a) providing a moveable mold part comprising at least a first moldcore; (b) providing a stationary mold part comprising at least a firstmold cover including a first cavity and a second mold cover including asecond mold cavity, the second cavity of greater volume than the firstcavity; (c) providing a decorative layer on the first mold cover acrossat least a portion of said first cavity; (d) aligning the first moldcover with the first mold core to form a first injection volume; (e)injecting a first polymeric material into said first injection volumebehind said decorative layer and solidifying said first polymericmaterial to form a decorative composite; (f) sequentially moving saidfirst mold core including said decorative composite with respect to thestationary mold part to selectively align the first mold core includingsaid decorative composite with the second mold cover, the second moldcover and said first mold core including said decorative compositeforming a second injection volume; (g) injecting a second polymericmaterial into the second injection volume formed between said decorativecomposite and said second mold cover to form an outer layer, wherein atleast one of said first polymeric material and said second polymericmaterial comprise a clear plastic; and (h) solidifying said secondpolymeric material to form a composite product.
 20. The method of claim19 wherein the stationary mold part comprises a first mold core and themoveable mold part comprises one or more mold covers.
 21. The method ofclaim 19 wherein the second polymer is a clear plastic.
 22. The methodof claim 21 wherein said clear plastic comprises any one ofpolycarbonate, poly(methyl methacrylate), thermoplastic urethane,polyester, copolyester alloy, cyclic olefin copolymer,poly-4-methyl-1-pentene, polysulphone, allyl diglycol carbonate, allylester, styrene-acrylonitrile, polystyrene, polyvinyl chloride andblends, alloys and combinations thereof.
 23. The method of claim 19wherein said decorative layer comprises one of a film, a foil, alaminate, a veneer, a fabric or a coating.
 24. The method of claim 23wherein said veneer includes a wood grain pattern.
 25. The method ofclaim 19 wherein one or more of said first or said second polymersincludes one or more pigments, tints, colored dyes, metallic flakes orlight reflective particles blended therein.
 26. A process formanufacturing a multi-layer composite product of injection moldedplastic comprising: (a) providing a moveable mold part comprising atleast a first mold cover including a first cavity; (b) providing astationary mold part comprising at least a first mold core including afirst projecting profile and a second mold core including a secondprojecting profile, the second profile smaller than the first profile;(c) providing a decorative layer on the first mold cover across at leasta portion of said first cavity; (d) aligning the first mold cover withthe first mold core to form a first injection volume; (e) injecting afirst polymeric material into said first injection volume between saiddecorative layer and said first mold cover and solidifying said firstpolymeric material to form a decorative composite; (f) sequentiallymoving said first mold cover including said decorative composite withrespect to the stationary mold part to selectively align the first moldcover including said decorative composite with the second mold core, thesecond mold core and said first mold cover including said decorativecomposite forming a second injection volume; (g) injecting a secondpolymeric material into the second injection volume formed between saiddecorative composite and said second mold core to form a backing layer,wherein at least one of said first polymeric material and said secondpolymeric material comprise a clear plastic; and (h) solidifying saidsecond polymeric material to form a composite product.
 27. The method ofclaim 26 wherein the stationary mold part comprises a first mold coverand the moveable mold part comprises one or more mold cores.
 28. Themethod of claim 26 wherein the second polymer is a clear plastic. 29.The method of claim 28 wherein said clear plastic comprises any one ofpolycarbonate, poly(methyl methacrylate), thermoplastic urethane,polyester, copolyester alloy, cyclic olefin copolymer,poly-4-methyl-1-pentene, polysulphone, allyl diglycol carbonate, allylester, styrene-acrylonitrile, polystyrene, polyvinyl chloride andblends, alloys and combinations thereof.
 30. The method of claim 26wherein said decorative layer comprises one of a film, a foil, alaminate, a veneer, a fabric or a coating.
 31. The method of claim 30wherein said veneer includes a wood grain pattern.
 32. The method ofclaim 26 wherein one or more of said first or said second polymersincludes one or more pigments, tints, colored dyes, metallic flakes orlight reflective particles blended therein
 33. An appliqué′ fordecorating or protecting a surface, comprising; a decorative layerincluding a top surface and a back surface; an injection molded plasticbacking layer formed on said back surface; and an injection moldedplastic outer layer formed on said top surface, wherein said outer layercomprises a clear plastic.
 34. The appliqué of claim 33 wherein saidclear plastic comprises any one of polycarbonate, poly(methylmethacrylate), thermoplastic urethane, polyester, copolyester alloy,cyclic olefin copolymer, poly-4-methyl-1-pentene, polysulphone, allyldiglycol carbonate, allyl ester, styrene-acrylonitrile, polystyrene,polyvinyl chloride and blends, alloys and combinations thereof.
 35. Theappliqué of claim 33 wherein said decorative layer comprises one of afilm, a foil, a laminate, a veneer, a fabric or a coating.
 36. Theappliqué of claim 33 wherein one or more of said backing layer and saidouter layer include one or more pigments, tints, colored dyes, metallicflakes or light reflective particles blended therein.
 37. The appliquéof claim 33 wherein said veneer includes a wood grain pattern.
 38. Amethod for manufacturing an appliqué having a decorative layer, abacking layer and an outer layer, comprising the steps of: (a) providinga mold core and mold cover which cooperate to form a cavity spacewherein said core and cover are aligned along one or more shearingedges; (b) providing a decorative layer having a front side and a backside; (c) placing said decorative layer across said mold cover overlyingat least a portion of said cavity space; (d) aligning said mold core andsaid mold cover to form a first injection volume therebetween; (e)injecting a first polymer against the front side of said decorativelayer to substantially conform said decorative layer against the coreside of said first injection volume thereby forming a decorativecomposite comprising an outer layer at least partially formed in frontof said decorative layer; (f) solidifying said outer layer; (g)retracting said core from said cover and removing said decorativecomposite; (h) providing a second mold core and second mold cover whichcooperate to form a second cavity space; (i) placing said decorativecomposite upon said second mold cover; (j) aligning the second moldcover and second mold core including said decorative composite to form asecond injection volume; (k) injecting a second polymer into said secondinjection volume against the back side of said decorative layer to forman backing layer; and (l) solidifying said second polymer to form amolded appliqué.
 39. The method of claim 38 wherein the second polymercomprises clear plastic.
 40. The method of claim 39 wherein said clearplastic comprises any one of polycarbonate, poly(methyl methacrylate),thermoplastic urethane, polyester, copolyester alloy, cyclic olefincopolymer, poly-4-methyl-1-pentene, polysulphone, allyl diglycolcarbonate, allyl ester, styrene-acrylonitrile, polystyrene, polyvinylchloride and blends, alloys and combinations thereof.
 41. The method ofclaim 38 wherein one or more of said first or said second polymersincludes one or more pigments, tints, colored dyes, metallic flakes orlight reflective particles blended therein.
 42. The method of claim 38wherein said decorative layer comprises one of a film, a foil, alaminate, a veneer, a fabric or a coating.
 43. The method of claim 42wherein said veneer includes a wood grain pattern.
 44. A method formanufacturing an appliqué having a decorative layer, a backing layer andan outer layer, comprising the steps of: (a) providing a mold core and amold cover which cooperate to form a cavity space wherein said core andcover are aligned along one or more shearing edges; (b) providing adecorative layer having a front side and a back side; (c) placing saiddecorative layer across said mold cover overlying at least a portion ofsaid cavity space; (d) aligning said mold core and said mold cover toform an injection volume therebetween; (e) injecting a first polymeragainst the backside of said decorative layer and injecting a secondpolymer against the front side of the decorative layer; and (f)solidifying said first and said second polymers to form a moldedappliqué′.
 45. The method of claim 44 wherein the position of thedecorative layer in said appliqué is determined by the timing of theinjection of the first and second polymers.
 46. The method of claim 44wherein one or both of the first polymer and the second polymer is aclear plastic.
 47. The method of claim 46 wherein said clear plasticcomprises any one of polycarbonate, poly(methyl methacrylate),thermoplastic urethane, polyester, copolyester alloy, cyclic olefincopolymer, poly-4-methyl-1-pentene, polysulphone, allyl diglycolcarbonate, allyl ester, styrene-acrylonitrile, polystyrene, polyvinylchloride and blends, alloys and combinations thereof.
 48. The method ofclaim 44 wherein said decorative layer comprises one of a film, a foil,a laminate, a veneer, a fabric and a coating.
 49. The method of claim 48wherein said veneer includes a wood grain pattern.
 50. The method ofclaim 44 wherein one or more of said first or said second polymersincludes one or more pigments, tints, colored dyes, metallic flakes orlight reflective particles blended therein.